Ergonomic Optimization of Assembly Workstations: Effects on Productivity and Mental Workload

Abstract

The main aim of this research paper is to improve the effectiveness of production processes through ergonomic optimization of industrial workstations where workers perform repetitive, monotonous assembly tasks. The study analyzes the impact of applying ergonomic and lean principles, standard of “the golden zone standard” in the design of assembly workstations on participants’ brain activity and productivity, as well as on the quality of the final products in traditional (non-ergonomic) and ergonomic scenario. The results indicated significant differences in brain activity patterns between the two scenarios, revealing higher levels of mental workload during assembly tasks in the non-ergonomic scenario for all participants. Furthermore, improvements in production processes were observed, including increased productivity; specifically, the average mental workload was reduced by approximately 35% in the ergonomic scenario, accompanied by an approximately 5% increase in productivity and an approximately 8% reduction in working time. The obtained results provide a foundation for improving the design of assembly workstations in industrial environments, as well as contributing to a broader understanding of the importance of ergonomics in the optimization of industrial processes.